Today’s Disruptive Technology Leader

Among the numerous emerging technologies in the process industries today, the digital twin is the most powerful.

Since the technology is so new, the concept is rapidly evolving—as are perceptions. Many people think of a digital twin as a 3D CAD model, probably because it is easily visualized and quite tangible. In fact, asset management is the simplest digital twin application. A facilities management inventory consists of digital representations of assets such as compressors, pumps, sensors, and valves. In addition to the 3D CAD representation, information such as model number, serial number, manufacturer, and maintenance history are available. Thus, the record for each asset can be considered a digital twin.

However, other implementations are much more than simply CAD models. Deeper thinking has opened up a new range of possibilities and technologies. A broader scope of entities can be considered as digital twins—not just “things” such as sensors or machines but also systems, humans and processes. In order to characterize their daily activities, numerous dynamics come into play. From physical objects to fluid flow, and inferred thermodynamics to electrolytic properties, a digital twin is able to emulate a complete scope of dynamics.

Yokogawa’s definition of a digital twin is a virtual, digital copy of a device, system, human or process….• that accurately mimics actual

performance,• in real time,• that is executable and can be

manipulated,• allowing a better future to be

developed.

Between Yokogawa and its affiliate, KBC-A Yokogawa Company, the digital twin portfolio is extensive. The digital twin solutions vary in scope, application and value. No digital twin is the same; this is why Yokogawa believes it is of utmost importance to focus not only on new technology but also on the problem or opportunity at hand.

The digital twins we are delivering in single, integrated environments across the full stream are both granular and system-wide:

• Advanced chemistry in pipes, vessels and units, including pressure, volume, temperature, and electrolytic chemistry

• Entire subsea production networks and topside facilities, including offshore power generation

• Process and utilities systems such as liquefaction plants, refineries and petrochemical plants

• Entire value chains, including the production or manufacturing facility, as well as the upstream and downstream components of the supply chain in which these facilities exist

• Human operator processes

• The list goes on…

Digital Twin

Today, a facility could have a multitude of digital twins existing across the traditional ISA95 Purdue Model architecture and further afield within the organization. As they are increasingly integrated and connected, the scope and scale of these “twins” will grow and their transformative effect will amplify. The more expansive and integrated the digital twin becomes, the larger the territory it encompasses. Digital twins are now emulating centralized engineering hubs, remote operations centers and integrated production centers.

According to the ARC Advisory Group, manufacturers are increasingly depending on their automation and enterprise solution suppliers to keep their plants running smoothly through enhanced services offerings. In order to help customers with digital twins in this regard, Yokogawa digital twin solutions are focused on delivering outcomes for customers: more revenue, less cost, better capital efficiency, maintained or reinforced license to operate; whether in the form of improved safety, less CO2, or community support.

They span the entire enterprise, from the shop floor right up to the boardroom, for example:

• Advanced Chemistry: Highly intelligent devices, such as pumps, flowmeters, transmitters, and chemical analyzers provide total insight into their ongoing performance as well as the ability to adapt to changing duty requirements throughout the measurement device lifecycle.

• Enterprise Insight: A series of business and financial Key Performance Indicators (KPI’s) are updated in real time, plan versus actual, as part of an enterprise-wide balanced scorecard for corporate situational awareness. Advanced logic is applied to real-time operations data to project current and future understanding of the business for executives.

A digital twin is a means to an end, not the end itself. The end has not changed. Industry must continue to strive for every result it can, such as:

• Operation with no safety incidents

• No unplanned outages

• Rigorous adherence to operating plans

• Nimble response to changes and disturbances

• A motivated and informed workforce

• A culture of profitability

A digital twin, as a part of digitalization efforts and digital transformation strategies, is simply a vehicle to achieve superior results in these areas—and to achieve them in a sustainable manner.

Among a few examples in our everyday world are aircraft engines, taxi transportation and music selections. The supplier-customer relationship is changing. It is becoming increasingly focused on outcomes and evolving away from micro-management of inputs.

While customers can continue to purchase inputs such as hardware, software and services, they can now also take the worry-free, as-a-service approach. In the latter, they use a subscription model to purchase outcomes such as equipment uptime—or power-by-the hour in the case of an aircraft engine. For taxi transportation, that would be getting from point A to point B as efficiently as possible.

The same principles apply to our human interactions. We could spend considerable time and effort micro-managing individuals on our respective teams—or we could measure their performance vs. KPIs.

While they might appear to be futuristic

concepts, the digital twin and digital

transformation are “here and now.”

The industry is already realizing their many

benefits and will continue to do so due to

their sustainability.